Prepared roofing



1,585,693 May 25 1926' T. ROBINSON PREPARED ROOFING Filed June l, 1925 5 M 6| n j Lange f 5SATTORNEYS product of the ,type the trade as prepa atented May 25, l926.

THOMAS ROBINSON, OF NEW YORK, N. Y.

ranrnnnn noorme.

Application ated .time l,

rlhis invention relates to a new rooting nerally referred to in rootings, and which is composed of various materials ot' a waterresistant character tormed into elements ot dierent kinds appropriate for roofing and general building purposes. More particularly the invention is intended to provide a new product which is cheap, duralole` easily laid, and of considerable rigidity, and which, when laid in place, gives the roof an attractive appearance. Also, the invention is intended to provide a product which is made of ingredients available at low prices, and which may be employed in the manufacture of the new product with low labor charges.

Prepared rooings of various kinds are now in Wide use and they afford numerous advantages over wooden shingles, tiles of vitreous materials, and other similar roofing elements. These pre ared roofings are not only much cheaper t an the materials heretofore employed, and may be handled and laid more conveniently, but, in addition', as compared with wooden shingles, they reduce the fire hazard materially. Such prepared products are sold commerciall in various forms, such as rolls and as singe and multi-unit shingles. That type which has met with the greatest commercial success includes a base of different materials, to the surface of which is customarily applied a. coating of a water-resistant product, over which is then placed a coating of a wearing material.

A typical exam le of such prepared roofing consists of a elt made of wool. rags, or other similar material, suitably felted together and saturated with asphalt. *Over one or both surfaces of this base is then applied a layer of asphalt of a melting point such that it will readily withstand solar heat, and on the surface of the element which is to lie uppermost'and thus be exposed to the weather, is applied a coating of crushed slate partially em nedded in the ashalt layer before the latter has thoroughly hardened.

Such products are satisfactory in many res ects although a product which includes a elt base deteriorates with more or less wat. serai no. aaa/e.

rapidity u on exposure to the weather, due to the rottm of the felt. When these elements take t e torni of shingles which are laid in courses inthe usual manner, having an. exposed margin, the rotting of the telt causes the exposed edges to warp and curl and the root becomes unsightly and may also have openings through which leakage' takes place. Another o .jection to such products lies in the fact that they are neary alwa s of unitorm thickness from one end to t ie other, and thus the ex osed margins are comparatively thin. 'it e appearance of the roof is much more sightly when the roofing elements covering it have a thickened butt, but such elements cannot be readily made with a felt base. Another major objection is that the products ordinarily used 1n making the base, such as felt, asbestos board, and the like, are quite expensive, so that the cost of these elements, while less than wood, is quite a substantial item in building construction.

The object of the present invention is to provide a new roofing product which may be manufactured at a lower cost than prepared roolings now in use, and in any of the shapes and forms desirable for building purposes. More specifically, the present invention involves t e provision of a product which includes a body member made up of comminuted inert material and a cementitions binder which is enclosed in a jacket ot a water-proof sheeted material. ln one form of the invention'this jacket is doubled or folded upon itself in such a way as to provide a guide which is useful in laying the elements in overlapping courses, and the doubled portion of the jacket serves not only to strengthen the element and render it more rigid, but also to give it added thickness at a point such that the elements of the course next above will appear to have a butt of somewhat greater thickness than is actually the case. The new product is composed throughout'of materials which do not deteriorate upon exposure to the weather and may readily be made in the tapered form, which is most suitable for roofing purposes. ln certain features the new element resembles the roofing product disclosed in my copending application filed April 10,

1925, Ser. No. 22,057, but differs therefrom in certain respects which will be made clear as this description proceeds.

For a better understanding of the invention, reference will now be made to the accompanying drawings, in which Figs. 1, 2and 3 are face views of multiple and single unit shingles constructed inl accordance with the present invention,

Fig. 4 is a longitudinal, sectional view of these elements.

Fig. 5 is a longitudinal, sectional view similar to Fig. 4, but showing the element at an intermediate stage in its manufacture,

Fig. 6 is a longitudinal, sectional view through the central portion of theelement made on an enlarged scale, and

Fig. 7 is a longitudinal, sectional view of a detail of the shingle shown in Fig. 3.

Fig. 8 is a sectional view similar to Fig. 7, but showing the relation of the shingles when laid in the ordinary manner in overlapping courses.

Referring now to these drawings, there is illustrated in Fig. l, a three-unit strip shingle 10 of the ordinary form, which 1s provided with cut-out portions 11, in its forward edge, which is the edge normally exposed when the elements are laid in courses. These cut-out indentations divide this edge of the element into tabs 12 which correspond in appearance to the ends of single unit elements. Thus, when a series of the multiunit shingles are laid in courses, the cut-out indentations defining the tabs give the roof the same appearance as it would have if covered with single unit shingles laid in spaced relation.

In Fig. 2 there is shown a single unit element 18 having cut-out portions 14 along either lateral edge at the forward end. These elements are also laid side by side in courses, with their rear portions 15 of their lateral edges lying in Contact While the cutouts 14 of adjacent shingles give these shingles the appearance of being spaced apart. The shingle 16 in Fig. 8 is the ordinary rectangular unit which is to be laid in courses but with the elements of the course spaced apart in the usual manner.

The new product may be made in any of the ordinary forms, such, for instance, as those illustrated, and others, and may be made eitherof uniform or tapering cross section from front to rear, the latter being preferable.

This element comprises, as shown lnore clearly in the other figures of the drawings, a jacket sheet 17, which is somewhat more than twice as long as the length of the element. This sheet is folded transversely, as at 18. This jacket may be made of various sheeted materials, of which a water-resistant paper, such as one impregnated with asphalt, is typical. It is preferably, though` maaeea not necessarily, water-resistant and should have a fair degree of strength. It serves to confine the body of the new product, and is particularly useful during the course of manufacture for this purpose. Also, it contributes a certain amount of strength and durability to the final product, although the resistance of the new material to water does not depend on this jacket to any considerable extent, nor is the rigidity of the product thus dependent. Accordingly, various materials other than asphalt paper will suggest themselves to those skilled in the art as being usefulfor the purpose. Such products as asbestos paper or coarse grade ordinary paper not impregnated, may be used also, although asphalt paper is perhaps preferable because it is Water-proof and it is of low cost.

A jacket sheet of the proper dimensions having first been secured, it is folded in the manner described, and then supported in any convenient way, preferably with its sides relieved from straln and spaced apart according to the thickness of the element to be produced. If this element is to be tapered, then the sides of the sheet are supported in diver-ging relation. In the fold of the sheetthus formed there is now introduced the filler which is made up of a comminuted, inert material, together with a cementitious binding compound. This inert material may be of Various kinds, as, for example, crushed slate, crushed petroleum coke, infusorial earth, sand, gravel, pumice stone, ground cork, fibrous products, such as asbestos and peat, and other similar materials of this character. The natural product known as asbestos sand, may also be used. This is a waste product in the manufacture o f asbestos which is entirely satisfactory in the manufacture of these elements and may be secured at an extremely low cost. The plastic binding compound employed'is preferably a bituminous substance, such as asphalt.

In the manufacture of the elements the filling material which goes to make u the body enclosed within the jacket sheet 1s introduced into the sheet while the latter is supported in folded relation. Prior to the introduction of the mass of filler, it is desirable to fold one ply of the sheet upon itself, as at 19. It will be seen from Fig. 6 that this fold involves the formation of a loop, the end of which is designated at 20, this loop being then bent to one side so as to lie against part of the ply ,21. The purpose of folding this ply of the sheet upon itself at this point is to give the element an added thickness and the transverse ply is preferably placed so that its forwart edge 20 delines the rear end of the normally exposed margin of the element. Also, as is apparent from Fig. 6, this increased thick- [ill titl

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ness of jacket material at this point, being overlain by the forward end of the elements in the course next above when the elements are laid in the usual way, raises the ends of these elements in such a way as to give them the appearance of having a much thicker butt than is actually the case. rll`he raisimY of the butt ends of the elements is brouglit out more clearly in Fig. 8, where it will be seen that the elements of one course are laid so that the butts are in substantial registry with the folds of the shingles of the course next beneath, and thus the exposed butts appear' to have a greater thickness than is actually the case. ylhus the fold at this point serves the purpose not only of giving the element transverse rigidity, of providing a guide for laying the elements of the course next above, but also of raising the exposed ends of these elements so as to give them the appearance of greater thickness. lin addition, the added thickness in the jacket at this point assists in preventing water from getting in between the elements. As the water is blown up the roof, and flows over the exposed faces of the elements, if there were no increased thickness at the point 20 the water would be free to flow directily between the face of one element and the under surface of the element above it. By making the element thicker at this point, thus providing a jog, as shown in Fig. 6, the water blown by the wind makes an abrupt change of direction and only part, if any, will flow on beyond the jog.

lin making these elements the body mixture is introduced into the fold 18 of the jacket, while the op osite plies of the jacket are held in the desired spaced relation and after the fold 19 has been formed. The mixture which ll have found to be highly satisfactory for the purpose is one consisting of asbestos sand and asphalt, the latter having a melting point such that it will withstand solar heat. This mixture is introduced into the jacket in the desired quantity, packed tight by suitable means, and then allowed to harden. f desired, the plies of the jacket may be cut so as to leave portions 22, which extend somewhat beyond the end of the body as shown at 23. Preferably before the body has completely hardened, these ends are turned inwardly so as to overlap, as shown more clearly in Fig.

' 4, so that both ends of the body and both faces are enclosed within the jacket, the lateral edges of the body only being exposed.

After the body has hardened to some extent, the cut-outs 11 and 14 may be formed in the forward edge of the element, and thereafter the entire element is given a surface coating of water-resistant material. such as asphalt. This material covers not only the jacket, the exposed end portions of the body, but also covers those portions of the body which would normally be exposed in the cut-out indentations. While this surface coating is still in a plastic condition, a wear surface is formed on the upper face of the body, and the body end, by applying a layer of comminuted material, such as crushed slate, indicatedvat 24. After the waterproof coating has hardened to the desired extent, the elements are ready for storage or transportation.

lf desired, the elements may be manufactured in the form of a continuous strip, the dierent operations being carried on prior to cutting the elements into the smaller units, and in this process the sheet of jacket material is drawn from a supply, folded as desired, filled, the cut-outs formed, and the various other operations carried on while the sheet is in movement. rlhis process is comparatively simple and permits the manufacture of the products at a low cost.

lin the element illustrated in Fig. 7, the upper ply 21 of the sheet has been formed with two loops, the under of which is designated 20, and the upper 25. rlhe upper fold of thev loop 20 extends rearwardly to the point 26, which is somewhat beyond the point 27, where the first fold in the sheet is made. lWith this arrangement, there are five plies of the material in the transverse thickened portion, and the sheet gradually tapers in thickness, as illustrated, so that there is no distinct bulge to the rear of thei jog which serves as the guide for laying the elements of the course above. If desired, both plies may be of the same width, and may be laid directly one upon another, and also. more than two folds such as are shown in Fig. 7, may be employed. ltwill be understood that the jacket material is somewhat thinner than as illustrated in Figs. l

to 7. inclusive, where the thickness of the sheet is somewhat out of proportion in order to make the illustration clearer. Ordinarily the length of the fold in the ply of the sheet from the point 20 to that designated 28 will vary from somewhat less than one inch to three inches, depending on the character of the element to be made, and the manner in which it is laid. The forward edge of the fold indicated at 20, which defines the rear edge of the exposed margin of the element, will also be placed at a point which will be determined bv the manner in which the elements are laid. Ordinarily the elements are laid in overlapping courses, so that the rear end of each element is overlapped by the forward ends of the elements in the two next higher courses. Consequently the element has a length which is equal to twice the width of the exposed margin plus a distance designated as the head-lap, which is the amount by which the element is overlapped by the elements in the second higher course.

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Accordingly, the line of the folding 2O will lie somewhat forward of the transverse median line of the element and in case the element is one having cut-outs as shown in Fig. 1, the line of fold will lie flush with the rear ends of the cut-outs.

In constructing the new product, I prefer to employ asphalt impregnated paper for the jacket and a mixture of asphalt and asbestos sand for the filler. Asbestos sand is a commercial product which consists of fine particles of asbestos substantially without fibre and sometimes includes a little gangue. This product has a somewhat lower specic gravity than asphalt. Consequently, when a mixture of asphalt and this material is introduced into the jacket, then the asbestos sand to a large extent remains suspended so that in the filler. that portion which occupies the fold in the jacket is composed nearly entirely of asphalt, While the portion at the buttwill contain most of the asbestos sand. By raising the temperature of the mixture so as to give the asphalt the desired fluidity, the asbestos sand will remain suspended and because of its less specific gravity than the asphalt, will in fact occupy the greater portion at the butt of the shingle. I have found that the rigidity of the element will vary to some extent, according to the density of the materials which form the filler, but when such a mixture is employed, as a filler or body in a tapered element, then the rigidity is not imp-aired because the heavier material, that is, the asphalt, will occupy the thinner part of the body, While the lighter material, that is, the mixture of asphalt and asbestos sand, will occupy the thicker portion or butt. Sincethe butt is of increased thickness, and there is a greater quantity of filler present at this point, the fact that the filler is comparatively lighter does .not reduce the rigidity of the element in any detrimental way. The desired gradation is effected by regulating the temperature of the mixture of asbestos sand and asphalt, and when the filler cools and sets the particles of asbestos sand remain in fixed position.

While I have described the advantages of providing the fold 19 in one ply of the Jacket sheet in some detail, in connection with an element in which no metal is used, I contemplate that it may be desirable in some instances to provide the exposed margin of the element, together with the butt end and the edges of the element adjacent this end, with a protective sheathing of metal which will take the form of a shell of appropriate shape applied to this portion of the element and held in place by suitable adhesive material. When such a shell of metal is to be applied to a base material, it is desirable to make some provision for covering the rear edge of the element so that naeaeea water cannot enter between the metal and the base and thus eventually bring about av separation of the base and the metal. 'Ihe new element herein described lends itself most satisfactorily to the manufacture of such a metal-clad product, because a preformed shell may be applied to the forward face of the element and its rear edge may be inserted between the ply 21 and the fold which terminates at the point 20. For this purpose it will simply be necessary to break the asphalt film along the forward edge of the fold at 20, then separate the two plies a slight distance so that the rear edge of the metal may be inserted between the ply 21 and the folded portion, the end of which is designated at 20. Prior to the introduction of the rear edge of the shell, the faces of the plies are coated with asphalt or some similar material of this character, a film of which is also applied over the end' of the fold along the line 20. The rear edge of the metal is thus held firmly in place and is entirely protected so that no water can enter between the base. and metal from the rear.

I claim:

l. A tapered roofing element comprising the combination of a body of hardened plastic material and a sheet folded over to enclose one end of the body, the two plies of the sheet also covering the opposite faces of the body and one of these plies being folded upon itself-to increase the thickness of the ply in a zone extending transversely of the element and spaced from the ends of the latter.

2. A tapered roofing element comprising the combination of a body of comminuted material and a cementitious binder and a sheet folded over one end of the body and covering the opposite faces of the body, one ply of the sheet being folded upon itself to provide a thickened portion extending transversely of the element, the forward edge of the thickened portion being coincident with the rear edge of the normally exposed margin of the element.

3. A tapered roofing element comprising the combination of a body of comminuted material and a cementitious binder, theA body having gradually increasing thickness from one end to the other, and a sheet folded over the thin end of the body and covering the opposite faces of the body, one ply of this sheet being folded into a loop which is bent to lie against the surface of the ply, this loop extending transversely of the element and lying spaced from the edges of the latter.

4. A taperedrooiing element comprising the combination of a body formed of a hardened plastic material and a sheet folded over to enclose one end of the body, the two plies of the sheet covering the opposite faces of the body and one of these plies being mariees? olded upon' itself to provide a plurality of )ops lying one upon another, the lowest loop ying afrainst the face of the ply and the )ops above being of successively greater vidth, these loops providing a band of inreased thickness extending transversely of he element and lying spaced from the ends hereof.

5. A tapered roofing element comprisin he combination of a body of comminute naterial and a cementitious binder, and a heet folded over to enclose one end of the |ody, the two plies of the sheet covering the lpposite faces of the body and one of these i ies being folded upon itself to provide a lurality of loops lying one upon another lnd parallel with the face of the ply, the forvard edges of these loops lying in registry ,nd also lying coincident with the rear edge f the normally exposed margin of the elenent.

6. A tapered roofing element comprising he combination of a sheet doubled upon it- 'elf to provide a fold with the plies of the heet diverging from the line of fold, and a od-y lying within the sheet and com rised f asbestos sand and asphalt, the density of he body varying from one end to the other Vith the denser portions lying nearer the hinner end of the element.

7. A tapered roofing element comprising he combinatioun of a body of hardened plasic material, a sheet folded over to enclose ne end of the body, the two plies of the zheet also covering the opposite faces of the iody, and one of these plies being folded lpon itself to increase the thickness of the )ly in a zone extending transversely of the element between the ends of the latter, and a :eating of a water-proof substance applied )ver the sheet and the exposed ends of the element.

8. A tapered roofing element comprising .he combination of a body of hardened plas- :ic material, a sheet folded over to enclose )ne end of the body, the two plies of the sheet also coverin the opposite faces of the Jody and one o these plies being folded ipon itself to increase the thickness of the -oly in a zone extending transversely of the lement between the ends of the latter, a mating )ver t e sheet and the exposed ends o the of a water-proof substance applied element, and a wear surface applied over the face of the sheet having the transverse fold and also over the end of the element.

9. A tapered roofing element comprising the combination of a body of hardened plastic material and a sheet folded over to enclose one end of the body, the two lies of the sheet also covering the opposite aces of the body and one of these plies being folded upon itself to increase the thickness of the ply in a zone extending transversely of the element between the ends of the latter, and one edge of the element being provided with a kplurality of cutout indentations defining ta s.

l0. A tapered roofing element comprising the combination of a body of hardened plastic material, a sheet folded over to enclose one end of the body, the two plies of the sheet also covering the opposite faces of the body and one of these plies being folded upon itself to increase the thickness of the ply in a zone extending transversely of the element between the ends of the latter, and one edge of the element being provided with a lurality of cut-out indentations defining ta s, and a coating of water-proof material applied tol the sheet and covering those portlons of the body which are exposed along either side of the sheet and also in the cutout indentations.

11. A tapered roofing element comprising the combination of a body of hardened plastic material, a sheet folded over to enclose one end of the body, the two plies of the sheet also covering the opposite faces of the body and one of these plies being folded upon itself to increase the thickness of the ply in a zone extending transversely of the element between the ends of the latter, and

.one edge of the element being provided with a plurality of cut-out indentations dening tabs, a coatin of water-proof material applied to the s eet and covering those ortionsr of the body which are exposed a ong either side of the sheet and also in the cutout indentations, and a layer of crushed mineral matter partially embedded in the waterproof coating and covering the end of the element and the face of the folded ply.

lin testimony whereof I affix my signature.

THOMAS aoBiNsoN. 

